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TCG120 _R1.18 - May 2022 Page 2
1. Short description
TCG120 is a GSM-GPRS remote monitoring controller for distributed IO monitoring and control. The
controller has 2 digital inputs, 2 analog inputs, and 1-Wire interface. The controller supports up to 4
Teracom humidity and temperature 1-Wire sensors. The device has 2 relays with normally open and
normally closed contacts.
The relays can be activated either remotely (via SMS or HTTP API command) or locally - from the status
of the monitored parameters. Only one parameter can control the relay at the same time, but for each
parameter, an email or SMS can be sent on an alarm condition.
TCG120 may periodically send data to a remote server, which makes it suitable for client-server
monitoring and control systems.
2. Features
• Quad-bands connectivity;
• Setup via USB, SMS and HTTP API;
• 2 digital inputs with " dry contact" and "logic level" modes;
• 2 analog inputs with 0 to 60 VDC range;
• 2 relays with NO and NC contacts;
• TST1xx, TST2xx and TSH2xx temperature and humidity 1-Wire sensors support;
• SMS alarm alerts to 5 numbers;
• Email alarm alerts to 5 email recipients, with TLS 1.2 support;
• Single call control from up to 100 numbers;
• Periodical HTTP post with current status in XML or JSON file to remote server;
• HTTP API commands;
• Firmware update over USB or GPRS.
3. Applications
• Remote control
The relay outputs can be controlled with SMS, HTTP command or by a single call from an
authorized number.
• Humidity and temperature control
TCG120 supports TST1xx, TST2xx and TSH2xx temperature and humidity- temperature 1-
wire sensors. The relay outputs can be controlled from the value of the measured
parameters.
• Status reporter
SMS and E-mail alerts can be sent to the authorized recipients. The alerts can be triggered if
some of the measured parameters (temperature, humidity, analog inputs, and digital
inputs) are in the alarm state.
• SCADA systems
TCG120 be easily integrated into SCADA systems. The periodical HTTP post is suitable for
client-server configurations.
TCG120 _R1.18 - May 2022 Page 3
4. Specifications
• Physical characteristics
Dimensions: 107 x 72 x 32 mm
Weight: 130 g
Mounting: wall
• Environmental limits
Operating Temperature: 0 to 40°C
Storage Temperature: -25 to 60°C
Ambient Relative Humidity: 5 to 85% (non-condensing)
• Standards and Certifications
Safety: EN 60950-1:2006+A11:2009+A1:2010+A12:2011+A2:2013; EN 61010-1:2010
EMC: EN 55022:2010, EN 55024:2010, EN 61000-3-2:2014, EN 61000-3-3:2013
EN 301489-1 V1.9.2, EN 301489-7 V1.3.1
RFSU: EN 301511 V9.0.2
Green Product: RoHS
• Warranty
Warranty period: 3 years
• Power requirements
Input Voltage: 10 to 28 VDC
Input Current: 240 mA @ 12 VDC
• Cellular interface
Standards: GSM/GPRS
Bands: 850/900/1800/1900 MHz
GPRS multi-slot class: 12, 1~12 configurable
GPRS terminal device class: Class B
Compliant to GSM Phase 2/2+: Class 4 (2W@850/ 900MHz), Class 1 (1W@1800/1900MHz)
SIM card size: Standard
Antenna connector: SMA-F
• Analog inputs
Isolation: Nonisolated
Type: Single ended
Resolution: 10 bits
Input Range: 0 to 60 VDC
Accuracy: ±1%
Sampling Rate: 500mS per channel (averaged value of 500 samples)
Input Impedance: 1 mega-ohms (min.)
TCG120 _R1.18 - May 2022 Page 4
• Digital inputs
Isolation: Nonisolated
Type: Dry contact and logic level
Minimum high-level input voltage for digital inputs: +2.5VDC
Maximum low-level input voltage for digital inputs: +0.8VDC
Maximum input voltage for digital inputs: +5.5VDC
Sampling rate: 10mS
Digital filtering time interval: 30mS
• Relay outputs
Type: Form C (N.O. and N.C. contacts)
Contact current rating: 3 A @ 24 VDC, 30 VAC (resistive load)
Initial insulation resistance: 100 mega-ohms (min.) @ 500 VDC
Mechanical endurance: 10 000 000 operations
Electrical endurance: 100 000 operations @ 3 A resistive load
Contact resistance: 50 milli-ohms max. (initial value)
Pulse output: 0.1 Hz at rated load
• 1-Wire interface
Output voltage: 5.0 ± 0.3 VDC
Maximum output current: 200 mA
• Internal FLASH memory
Endurance: 100 000 cycles (Every relay status and settings change is a memory cycle)
5. Installation
This device must be installed by qualified personnel. The installation consists of mounting the device,
connecting to the GSM network, connecting inputs and outputs, providing power and configuring via a
web browser. This device must not be installed directly outdoors.
Attention! Before installing the SIM card in the card slot, please ensure that the PIN code is
disabled.
5.1. Mounting
TCG120 should be mounted in a clean and dry location on a not flammable surface. Ventilation is
recommended for installations where the ambient air temperature is expected to be high.
Mount the device to a wall by using two plastic dowels 8x60mm (example Würth GmbH 0912
802 002) and two dowel screws 6x70mm (example Würth GmbH 0157 06 70). Attach the screws to
the surface vertically. See Appendix C, fig. 1 for mechanical details.
Maintain spacing between adjacent equipment. Allow 50 mm of space on all sides, as shown in fig.2
in Appendix C, this provides ventilation and electrical isolation.
5.2. Connectors
Attention! Disconnect power supply before wiring.
The correct wiring procedure is as follows:
• Make sure power is turned off;
• Make wiring connections to the terminals;
• Apply power.
It is recommended to test and configure TCG120 without any controlled device.
TCG120 _R1.18 - May 2022 Page 5
Make sure that wires are properly attached to the terminals and that the terminals are tightened.
Not proper wiring and configuration can cause permanent damage of TCG120 or the equipment to
which it is connected or both. Inputs and outputs locations are shown below:
Connector 1 – Power - 2.1x5.5mm connector,
central positive
Connector 2, Pin1 - Digital input 1 (Din1)*
Connector 2, Pin2 - Digital input 2 (Din2)*
Connector 2, Pin3 - Ground
Connector 2, Pin4 - Analog input 1 (Ain1)
Connector 2, Pin5 - Analog input 2 (Ain2)
Connector 2, Pin6 - Ground
Connector 2, Pin7 – 1-Wire data
Connector 2, Pin8 – 1-Wire power supply
Connector 3 – mini USB
Connector 4 – SIM card holder
Connector 5 – GSM Antenna
Connector 6, Pin1 – NC Relay2
Connector 6, Pin2 – COM Relay2
Connector 6, Pin3 – NO Relay2
Connector 7, Pin1 – NC Relay1
Connector 7, Pin2 – COM Relay1
Connector 7, Pin3 – NO Relay1
* Operating mode is selected by jumper DI1/DI2 - closed for “dry contact” and open for “logic
level”. By default, jumpers are closed.
5.2.1. Power supply connection
TCG120 is designed to be supplied by adapter SYS1308-2412-W2E or similar, intended for use in
the conditions of overvoltage category II. The power supply equipment shall be resistant to short
circuit and overload in the secondary circuit.
When in use, do not position the equipment so that it is difficult to disconnect the device from
the power supply.
5.2.2. Digital inputs connection
Attention! Digital inputs are NOT galvanic isolated.
The TCG120 digital inputs can be used in two modes – “dry contact” and “logic level”. The mode
is determined by the jumper, close to the corresponding input. To change the operation mode,
the plastic enclosure must be opened. Closed jumper determines “dry contact” mode while open
“logic level”. By default digital inputs are in “dry contact” mode.
In “dry contact” mode digital inputs can be used to monitor the state of a discrete device – door
contact switch, push button, PIR detector etc.
The following picture illustrates how a dry contact switch can be connected to the input (or
inputs) of TCG120. One side of the contact is connected to “Digital In” and the other side is
connected to “GND” terminals.
The maximum cable length for a digital input should be up to 30 meters.
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5.2.3. Analog inputs connection
Attention! Analog inputs are NOT galvanic isolated.
Analog inputs of TCG120 can be used for monitoring of DC voltage up to 60VDC. They can be
connected directly to batteries, solar panels, power supplies etc.
Built-in functionality “Multiplier”, “Offset” and “Dimension” for every analog input gives the
possibility to monitor sensors with analog outputs and see directly the measured parameter. It is
also possible to monitor voltages higher than 60 VDC with external resistive dividers.
The following picture illustrates how a battery can be connected to the analog input of TCG120.
One side of the contact is connected to “Analog In” and the other side is connected to “GND”
terminals.
The maximum cable length for a digital input should be up to 30 meters.
5.2.4. Sensor connection
The device supports TST1xx, TST2xx and TSH2xx temperature and humidity-temperature sensors.
Up to 4 1-Wire sensors can be connected to the controller.
1-Wire is a registered trademark of Maxim Integrated Products, Inc. It is designed to connect
several sensors over a short wiring. It is not suitable for long distances or environments with
EMC interference. We recommend reading Maxim’s 1-Wire tips at http://www.maxim-
ic.com/app-notes/index.mvp/id/148.
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The sensors have three wires – positive voltage (+VDD), ground (GND) and bidirectional data
(Data). The colors of wires for every sensor are specified in its user manual.
It is strongly recommended to use “daisy-chained” (linear topology) for multiple sensors:
“Star” topology can be used only as a last resort for up to 4 sensors and total cable length up to
10 meters:
There are many parameters which determine the maximum length of the wires - type of cable,
the number of sensors, ambient electromagnetic noise and sensor network topology.
It is strongly recommended to use only UTP/FTP cables and keep total cable length up to 30 m.
Although functionality has been achieved in the longer distance, we cannot guarantee error-free
operation over mentioned wiring length.
We guarantee proper operation only with Teracom 1-Wire sensors.
TCG120 _R1.18 - May 2022 Page 8
5.2.5. Relay connection
The relay contacts are internally connected directly to the terminal connectors. For all relays
normally open, normally closed and common contacts are available. For loads with higher
switchable current/voltage than specified, an external relay should be used.
When mechanical relays switch inductive loads such as motors, transformers, relays, etc., the
current will arc across the relay contacts each time the contacts open. Over time, this cause
wears on the relay contacts which shorten their life. When switching an inductive load, it is
recommended that relay contact protection devices are used.
6. LED indicators
LED indicators show the status of the controller:
• REL1 – REL2 (green) – the LED is ON when the corresponding relay is activated (the NO
contact is connected to COM);
• SIG (red) – indicates the status of the device together with STA
• STA (yellow) – indicates the status of the device together with SIG.
The following states are displayed:
• Controller initialization – after power-on and firmware update SIG and STA turn ON for a
second, after this turn OFF for another second.
• Searching for GSM network – after initialization, SIG is OFF, STA flashes (flash length –
200ms)
• Connected to GSM network – after successful connection to a mobile network, STA shows
the type of connection, while SIG shows the signal strength.
STA flashes ones for 200mS in period of 2S – there is GSM connection only;
TCG120 _R1.18 - May 2022 Page 9
STA flashes twice for 200mS in a period of 2S – there is GSM and GPRS connection.
At the same time SIG has 5 states:
SIG flashes 1 time in period of 2S – signal strength is between 0 and 20%;
SIG flashes 2 times in period of 2S – signal strength is between 21 and 40%;
SIG flashes 3 times in period of 2S – signal strength is between 41 and 60%;
SIG flashes 4 times in period of 2S – signal strength is between 61 and 80%;
SIG is solid ON – signal strength is between 81 and 100%;
• Error message – in case of error after initialization, SIG will stay solid OFF, STA will flash
showing the type of error.
STA flashes ones for 1S – master phone number is not set;
STA flashes permanently for 1S in a period of 2S – permanent hardware error.
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7. Initial setup via USB
The initial setup of TCG120 controller is done with a computer running Windows 7 or newer Microsoft
Windows operating system. After power-up, the controller should be connected to the computer with
USB cable. Once the USB cable is connected, the operating system automatically starts to install the
drivers for the communication with the device. The following message appears:
The following drivers will be installed:
- Microchip composite device
- USB serial port driver
If for some reason the USB serial port driver cannot be installed automatically, it must be installed
manually. The driver can be downloaded from the TCG120 product page at
www.teracomsystems.com. After successful driver installation, the device will be recognized as Mass
storage, the following window appears on the screen:
The only file stored on the mass storage is a tool called “TConfig”. This tool enables the communication
between the TCG120 and PC. After starting the TConfig tool, the following program will appear:
Pressing the “Start” button will start your web browser and display the Monitoring page of your
TCG120 controller.
TCG120 _R1.18 - May 2022 Page 11
7.1. Monitoring page
Monitoring page displays the current I/O state of TCG120 controller. The page has 4 sections –
“Sensors”, “Digital inputs”, “Analog inputs” and “Relays”.
For every parameter (sensor, input, relay) there is a description of up to 20 characters. The default
descriptions can be changed in “Setup-Input/Output” menu.
The Monitoring page is automatically refreshed every second.
7.1.1. Sensors section
All detected 1-Wire sensors are shown in this section. Sensor detection is done either after
power-on or by pressing “Scan for new sensors” button. All found sensors are shown in
ascending order refer their unique ID number. For every sensor, there are a description, value,
and ID information.
Teracom temperature sensors readings are shown in the Value 1 column. TSH2xx temperature-
humidity sensors have the 2nd parameter shown on the Value 2 column.
It is possible to lock a sensor on a specific position. To do this all sensors should be added one by
one. After every addition, a new scan should be done and newly found sensor should be locked
on the position. If all sensors are locked, removing one “in the middle” will not change the
positions of following sensors after reset.
7.1.2. Digital inputs section
Digital inputs can be used for monitoring the state of discrete devices – motion sensor, door
contact, relay contact, alarm output etc.
Digital inputs are sampled every 10mS. The change of input status is considered valid if the same
value is read in 3 consecutive samples (30mS).
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Status of every input is shown by text and by color.
The default descriptions and status names can be changed in “Setup-Input/Output”.
7.1.3. Analog inputs section
Analog inputs can be used for monitoring of DC voltage sources – analog sensors, batteries,
power supplies, solar panels etc.
Analog inputs are sampled faster, but the new actual value is changed in 0.5 seconds. All 250
readings between the value changes are averaged.
For every analog input “Unit”, “Multiplier” and “Offset” can be set in “Setup-> Input/Output”
section.
7.1.4. Relay section
The section displays the current state of the relays. Each relay can be activated either remotely
or locally from the status of a monitored parameter. For locally activated relays a text description
of the controlling parameter is displayed rather than buttons. It is possible to disable locally
control for a while from checkbox “Enable”.
Pulse duration and parameters for local relay activation can be set separately for each relay in
“Setup->Input/Output->Relay outputs”. In the time when a pulse command is executed, a new
pulse command is rejected.
7.2. Setup
7.2.1. SMS/Call
7.2.1.1. SMS Setup
SMS Alarm recipients can be set in this section.
The “Master” has special rights to change the device settings using SMS commands. This
number always receive the SMS alarm messages.
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The remaining 4 recipients can receive SMS messages if any of the parameters is in alarm
state. To receive SMS messages, the number should be enabled in the checkbox “Alarm
Notification”. These 4 recipients can also ask by SMS for parameter state/value.
By pressing “send test SMS” button all SMS recipients will receive a test SMS.
All commands, their syntax, and answers are described in “Setup via SMS”.
7.2.1.2. Phone call Setup
The relay outputs of TCG120 controller can be controlled (only pulse) by a single call from an
authorized number. The maximum number of the authorized numbers is 100. These numbers
can be set manually or by sending an SMS message from the Master.
7.2.2. SMTP
7.2.2.1. SMTP Setup
Mail server address can be set either by hostname (for example mail.teracomsystems.com) or
IP address.
The e-mails can be sent with or without an encrypted connection.
The default SMTP port without encryption is 25. Almost all ISP’s block this port to avoid
hacker’s attacks. Ask your ISP for details.
The only supported method for encrypted connection from most of the public email servers is
TLS. TCG120 supports TLS 1.0, TLS 1.1 and TLS 1.2 with RSA_WITH_AES_128_GCM_SHA256
and RSA_WITH_AES_128_CBC_SHA cipher suites. This ensures successful operation with
almost all public servers. STARTTLS is not supported.
Be careful with the terms SSL, TLS, and STARTTLS used in email server settings, supplied by the
provider. Some providers as Gmail uses SSL instead of TLS and TLS instead of STARTTLS. This
can provoke mismatches with the port number.
Sender e-mail, username, and password are standard authentication details. For the most
SMTP servers, sender's e-mail and username are the same.
There is a button for server settings test with a feedback. In this test sender and recipient of
the e-mail is the same.
7.2.2.2. Alarm destination
Up to 5 email recipients can be set. Every recipient can be activated independently by a
checkbox.
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7.2.2.3. Email details
The subject, body header, body and body footer can be customized. For this customization, a
set of keys is used. All they are described on the page.
7.2.3. Input/Output
7.2.3.1. Sensors
For every sensor, a description, up to 20 symbols can be set. These descriptions will appear on
the monitoring page, conditions page, XML/JSON data, SMS and e-mail alerts.
7.2.3.2. Analog inputs
For every analog input, a description, up to 20 symbols can be set. These descriptions will
appear on the monitoring page, conditions page, XML/JSON data, SMS and e-mail alerts.
For every analog input, fields “Unit”, “Multiplier” and “Offset” are available to convert the raw
voltage/current into meaningful engineering units. The shown value is calculated by:
DV[Un] = (AV – OF) * MU
Where:
DV – displayed value;
Un – unit;
AV – real analog voltage from source;
MU – multiplier in dimension [parameter/Volt];
OF – offset.
Example:
For humidity sensor HIH-4000-003 following parameter (coming from datasheet) should
be set for fine work:
TCG120 _R1.18 - May 2022 Page 15
Unit - %RH
Offset - 0.826
Multiplier - 31.74, the value is inversed of slope parameter (1/0.0315);
If the output voltage of this sensor is 3.198V on the monitoring page will be shown
75.28% RH:
75.28 = (3.198 – 0.826) * 31.74
By default and after “Factory default settings” procedure:
Unit - V
Offset - 0.00
Multiplier - 1.00
7.2.3.3. Digital inputs
For every digital input, a description, up to 20 symbols and states up to 20 symbols can be set.
These descriptions will appear on the monitoring page, conditions page, XML/JSON data, SMS
and e-mail alerts.
7.1.1.2. Relay outputs
For every relay description, up to 20 characters can be set. These descriptions will appear on
the monitoring page, XML/JSON data, SMS and e-mail alerts.
The pulse duration can be different for both relays. The resolution is 0.1 second, the
maximum pulse value is 3600 seconds.
Both relays can be activated either remotely by SMS/single call/HTTP command or locally
from the status of a monitored parameter. This setting is made from the “Activated from”
drop-down menu, the possible options are:
• SMS/HTTP - by selecting this option the relay outputs can be activated by SMS from
authorized number or by sending HTTP command (detailed description in “Push
mode” section);
• Phone call - by selecting this option the relay outputs can be activated (pulse only) by
a single call from an authorized number.
For local activation, alarm conditions for different sources are used. They are set up in section
“Setup->Conditions”. Following choices to assign a parameter to relay are possible:
• S? – “S” stands for “Sensor 1-Wire”. The relay is activated from a value measured
from specified 1-Wire sensor and rules for ranges specified in “Setup->Conditions”.
Question mark masks number from 1 to 4;
• Analog input? The relay is activated from a value measured from specified analog
input and rules for ranges specified in “Setup->Conditions”. Question mark masks
number from 1 to 2;
• Digital input? The relay follows the state of the specified digital input. Question mark
masks number from 1 to 2;
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The drop-down menu “Action on alarm/event” specifies which action will take place when the
alarm/event occurs. Following choices are possible:
• Turn on – the relay will turn on and will remain on until the parameter stays in alarm
state;
• Single pulse – the relay will be activated for the set pulse duration.
7.2.4. Conditions
This section is used for parameterization of the trigger and alert conditions for 1-Wire sensors,
analog, and digital inputs.
7.2.4.1. 1-Wire sensors and analog inputs
For every sensor two type of fields are presented – one for the trigger conditions (“Min”,
“Max” and “Hys.”) and another one for the wanted action.
“Min” and “Max” indicate the border of working range for the monitored parameter. A “Max”
trigger condition occurs when the value exceeds the trigger set point. A “Min” trigger
condition occurs when the value is lower than the trigger set point. In both cases, the
monitored parameter goes out of range.
Coming back in range for the monitored parameter is considered when the value goes higher
than (Min + Hys) or lower than (Max – Hys). Hysteresis (“Hys”) is used to prevent excessively
triggering when the value fluctuates around the trigger point.
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Example:
TCG120, TST100, and appropriate heater are used to control the room temperature. The
wanted minimum temperature is 19°C. The initial temperature is 17°C.
TST100 is assigned to the first position for 1-Wire sensors.
For Relay1 local activation from Sensor1 is set.
Following parameters are set for Sensor1: Min=19, Max=100 and Hys=0.5.
When the controller is switched on, Relay1 is immediately activated because the monitored
temperature is out of range. This switches the heater on. The temperature rises.
When the temperature reaches 19.5°C (19.0 + 0.5) it goes in range (trigger condition) and
Relay1 is deactivated. The heater is switched off.
The temperature falls and when it reached 19°C it goes out of range (trigger and alert
conditions). The relay is activated (heater is switched on) and e-mail is sent.
TCG120 _R1.18 - May 2022 Page 18
The “Max” value is set far enough from the wanted temperature to avoid trigger/alert
conditions around it.
For every sensor or analog input, there are 3 independent ways of alert when there is an
alarm condition – email, SMS, and post (HTTP post with XML/JSON file). Each alarm
notification method is activated by a checkbox.
Globally for all sensors and for all analog inputs, there is a checkbox “Return notification”. If
this option is chosen there will be notification also when parameter returns in range.
Globally for all sensors and for all analog inputs, there is a “Notification delay” parameter. It is
very useful like a filter for short alarm conditions.
7.2.4.2. Digital inputs
For every digital input, the alarm state should be chosen – Open or Close.
When the input goes in alarm state 3 independent alert actions are possible – email, SMS, and
post (HTTP post with XML/JSON file). Each alarm notification method is activated by a
checkbox.
Globally for all digital inputs, there is a checkbox “Return notification”. If this option is chosen
there will be notification also when parameter returns in range.
Globally for all digital inputs, there is a “Notification delay” parameter. It is very useful like a
filter for short alarm conditions.
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In the time when the input is in an alarm state, on „Monitoring page“, the appropriate input
will be colored in red.
There are two delays - low-to-high and high-to-low for digital input change. These delays are
added to the standard delay of 30mS. They have 0.1-second resolution and by default are
zero.
These options can be used for additional filtering.
7.2.5. System
The page for some general settings.
7.2.5.1. System status
There is information about the general status of the controller here.
The only possible setting here is “Data in roaming” checkbox. By default, it is disabled to avoid
extra charges for data transfer in roaming.
If you are using another operator's card, you must activate “Data in roaming”. Otherwise, you
will not be able to use all GPRS services – emails, HTTP Post, NTP, etc.
7.2.5.2. GPRS setup
To set the GPRS connection it is necessary to enter the APN (Access Point Name). This setting
can be different for each GSM service provider. By default, it is set to “internet”. Some
providers may require also username and password.
7.2.5.3. Mobile network connection reset
For areas with low signal strength or where the mobile network frequently drop/block,
automatic restarting of the network connection can be used. This could prevent permanently
losing the connection with the device.
The automatic restart will be done once per day.
By default, the automatic restart is disabled.
TCG120 _R1.18 - May 2022 Page 20
7.2.5.4. General setup
The section for some general settings.
The temperature and pressure units can be changed with preferable ones.
Writing mode change the alignment in the WEB interface and SMS.
Hostname, System name, System location, and System contact are sent in XML/JSON files and
can be used for flexible identification of the device. These parameters can be also included in
the body of the e-mails.
The checkboxes on the right define what to be displayed on the “Monitoring page”. By
default, they all are enabled.
7.2.5.5. Device restart
In this section there are tools for full device restart and reset to factory default settings.
7.2.6. Time
Internal RTC (real-time clock) of the controller can be set automatically only.
For automatic clock synchronization, the controller supports NTP (Network Time Protocol) and all
necessary parameters for automatic synchronization are available in this section.
The clock synchronization is made on “Interval” time. If the attempt was not successful, the next
synchronization will be on “If not found” time.
Pressing the “Save and synchronize” button initiates time synchronization. The information for
“Status” in the blue box is very useful for the availability of time server and Internet at all.
The current system time is sent in XML/JSON file when HTTP Post is enabled
By default, NTP server – time.google.com, port - 123, Timezone +00:00 and interval of 12 hours.
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